Soup box container

ABSTRACT

A container assembly for use in containing a food product includes a receptacle having a mouth defining an opening. The container assembly also includes a sleeve having a plurality of sidewalls forming a cavity and a cover engaging with the sidewalls and covering the cavity. The cavity at least partially retains the receptacle therein. The cover includes a rim defining an aperture for receiving the mouth of the receptacle therethrough.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/940,889 filed Feb. 18, 2014, hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The invention relates to a container for transporting food products and more particularly to a container assembly for transporting and thermally insulating soup.

BACKGROUND OF THE INVENTION

Many commercial prepared food retailers, restaurants, catering services, and the like provide catering, delivery, or to-go services for consumers for multi-person gatherings such as meetings, parties, or other events. Due to factors such as speed, affordability, and health, soup has become an increasingly common and desired food option for consumers. In order to provide for multi-person gatherings, portable bulk soup containers exist in order to transport the soup from the food provider's facility to the designated location of the gathering.

However, many problems exist in transporting soup. Initially, certain soups must maintain a certain range of temperatures for quality assurance and/or regulatory reasons. Current containers are unable to substantially maintain the desired range of temperatures of the soup. Additionally, soup ladles or other similar serving utensils are the simplest and efficient means for serving soup from the container to an individual. However, some bulk soup containers do not provide an opening that is large enough or an ergonomic shape that is conducive to receive the soup ladle or serving utensils while also providing an efficient means for filling the container with the food product. Furthermore, some bulk soup containers can be unwieldy and unable to withstand the weight of the bulk soup. Certain containers can also be difficult to assemble.

It would therefore be desirable to provide a portable container assembly for transporting soup that is sturdy, ergonomically configured, and substantially maintains a desired temperature of the soup that can also be easily manufactured and assembled.

SUMMARY OF THE INVENTION

Compatible and attuned with the present invention, a portable container assembly and method of assembling a portable container assembly for transporting soup that is sturdy, ergonomically configured, and substantially maintains a desired temperature of the soup that can also be easily manufactured and assembled has surprisingly been discovered.

According to an embodiment of the invention a container assembly for use in containing a food product is disclosed. The container includes a receptacle having a mouth defining an opening. The container assembly also includes a sleeve having a plurality of sidewalls forming a cavity and a cover engaging the sidewalls and covering the cavity. The cavity at least partially receiving the receptacle therein. The cover includes an aperture for receiving the mouth of the receptacle therethrough.

According to another embodiment of the invention, a container assembly for use in containing a food product is disclosed. The container assembly includes a receptacle having a mouth defining an opening and an insulation layer at least partially enveloping the receptacle. The container assembly also includes a sleeve having a plurality of sidewalls forming a cavity and a cover hingedly coupled with a first one of the sidewalls. The cavity at least partially receiving the receptacle and the insulation therein. The cover includes an aperture for receiving the mouth of the receptacle therethrough.

According to a further embodiment of the invention, a method of assembling a container assembly is disclosed. The method includes the steps of providing a blank including a plurality of side panels, a plurality of bottom flaps each hingedly coupled to a first end of one of the plurality of side panels, and a top panel hingedly coupled to a second end of a first one of the side panels. The method further includes the step of arranging the side panels, the bottom flaps, and the top panel to form an outer shell having a plurality of sidewalls and a cover. The cover includes a rim defining an aperture formed therein. A receptacle and an insulation layer are provided. The receptacle having a mouth defining an opening configured for receiving a food product. The receptacle is enveloped with the insulation layer. The method includes disposing the receptacle and the insulation layer in the outer shell and positioning the top cover in a closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings which:

FIG. 1 is a top perspective view of a container assembly according to an embodiment of the invention;

FIG. 2 is an exploded top perspective view of the container assembly of FIG. 1; and

FIG. 3 is a top plan view of a blank for forming the outer shell of the container assembly of FIGS. 1-2.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. The terms “bottom,” “top,” and “side” are for purposes of relative orientation only and not as an absolute position. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.

FIGS. 1-2 illustrate a portable container assembly 10 configured to contain and transport liquid or semi-liquid food products such as soup according to an embodiment of the invention. However, it is understood the container assembly 10 can be used to contain other food products such as sauces, gravy, dips, drinks, or any other liquid, non-liquid, or semi-liquid food products, as desired. The container assembly 10 includes a receptacle 12, an insulation layer 14, and a sleeve 16.

The receptacle 12 is configured for receiving the food product and may or may not include a handle. In certain embodiments, the receptacle 12 is formed of plastic such as high density polyethelyne configured to tolerate a food product with a high temperature. Other materials such as polypropylene, polycarbonate, polyethylene pterethalate (PET), polyvinyl chloride (PVC), or other plastics can be employed depending on the desired food product, and the temperature thereof, to be received in the receptacle 12. However, it is understood the receptacle 12 can be formed from any durable material as desired such as metal or foam, for example, without departing from the scope of the instant disclosure. In a non-limiting example, the receptacle 12 is a bulk soup receptacle configured to contain soup in bulk such as a receptacle configured to contain 64 ounces or 128 ounces.

The receptacle 12 includes an annular mouth 17 defining an opening 18 configured to receive the food product and a serving utensil 15 therethrough. The mouth 17 can be any dimension as desired. In a non-limiting example, the diameter is greater than 110 millimeters or larger to facilitate receiving the utensil 15. A lid 19 is coupled to the mouth 17 of the receptacle 12 to selectively cover the opening 18 of the receptacle 12. The receptacle 12 is any receptacle such as a bottle or pouch, for example, configured to hold food products according to safety and regulatory requirements.

The receptacle 12 is at least partially received by the insulation layer 14. The insulation layer 14 is configured to insulate the receptacle 12 containing the food product and substantially maintain a temperature thereof. In certain embodiments, the insulation layer 14 is configured to substantially maintain the temperature of a cold food product or substantially maintain the temperature of hot food product. In certain embodiments, the insulation layer 14 is a preformed multi-layer bubble foil wrap formed by a heat seal process that envelopes a portion of the receptacle 12. However, the insulation layer 14 can be any material configured to insulate the receptacle 12 such as a foam, an expanded polystyrene (EPS), a wood based material, a foil, or any other material or combination of materials configured to insulate the food product, for example. Additionally, it is understood the insulation layer 14 can envelope an entirety of the receptacle 12, if desired.

The receptacle 12 and the insulation layer 14 are received within the sleeve 16, wherein the insulation layer 14 is interposed between the receptacle 12 and the sleeve 16. The sleeve 16 is collapsible and includes a bottom 25 having an automatic bottom set-up, constructed by means of hinged-together bottom flaps (further described hereinbelow), that securely closes the bottom 25 of the sleeve 16. However, it is understood the sleeve 16 can include other types of bottoms now known or later discovered without departing from the scope of the disclosure. The sleeve 16 is formed from a material such as solid bleached sulphate (SBS) paperboard, E-flute corrugated, or any other style fiberboard. The sleeve 16 includes a first sidewall 26 a, a second sidewall 26 b, a third sidewall 26 c, and a fourth sidewall 26 d cooperating with each other to define a cavity 28 for receiving the receptacle 12 and the insulation layer 14. It is understood, the sleeve 16 can include any number of sidewalls such as more than four sidewalls or fewer than four sidewalls, as desired.

The sleeve 16 includes a cover 20. The cover 20 has a top wall 21, a first partition 30 a, a second partition 30 b, and a third partition 30 c. The top wall 21 is hingedly coupled to the fourth sidewall 26 d for movement between a closed position, as shown in FIG. 1, and an open position, as shown in FIG. 2. The partitions 30 a, 30 b, 30 c extend from the top wall 21 and partially overlap the first sidewall 26 a, the second sidewall 26 b, and the third sidewall 26 c. It is understood more than or fewer than three partitions can be employed, as desired. In certain embodiments, a slot 22 is formed in the top wall 21. The slot 22 is configured for receiving the utensil 15. More than one slot 22 can be formed in the cover 20, as desired, to receive various utensils.

In the embodiment illustrated, the cover 20 further includes a first pair of tabs 32 cooperating with a first pair of slits 34 configured to facilitate forming and reinforcing the cover 20. The first pair of slits 34 are formed adjacent an edge of the top wall 21 and the first pair of tabs 32 extend from the first partition 30 a. A second pair tabs 31 cooperating with a second pair of slits 33 are configured to maintain the cover 20 in the closed position. The second pair of slits 33 are formed in the second partition 30 b and the third partition 30 c and the second pair of tabs 31 extend from opposing sides of the first sidewall 26 a. Additional tabs and slits can be employed as desired. Other engagement means can be employed to facilitate forming and reinforcing the top cover 20. For example, adhesive and fasteners could be used in addition to or in lieu of the tabs 31, 32 and the slits 33, 34.

The cover 20 includes a rim 23 defining an aperture 24 formed in the top wall 21 thereof. The aperture 24 is configured to receive a portion of the receptacle 12. The aperture 24 substantially corresponds to a shape of the mouth 17 of the receptacle 12. In the embodiment illustrated, the rim 23 includes a substantially curvilinear portion 23 a and a substantially linear portion 23 b to define a segmented circular shape of the aperture 24. The linear portion 23 h is configured to engage with the mouth 17 of the receptacle 12 to secure the cover 20 in the closed position. However, it is understood the rim 23 can include any number of curvilinear or linear portions to define any shape of the aperture 24, as desired, such as circular, ovular, polygonal, or any other shape for example.

The sleeve 16 further includes a handle 36 coupled thereto and configured to facilitate transporting the container assembly 10. The handle 36 shown is an elongate plastic rope handle having substantially T-shaped ends. Each of the ends of the handle 36 is inserted through a respective slot 38 formed in the second sidewall 26 b and the third sidewall 26 c of the sleeve 16. The ends of the handle 36 engage with an interior surface of the sidewalls 26 b, 26 c so that the handle 36 can support the container assembly 10 during transportation thereof. It is understood other handle types and configurations can be used, as desired.

The sleeve 16 further includes a first flap 40 a, a second flap 40 b, and a third flap 40 c hingedly coupled to and extending from the first sidewall 26 a, the second sidewall 26 b, and the third sidewall 26 c, respectively. The flaps 40 a, 40 b, 40 c are configured to converge inwardly towards the mouth 17 of the receptacle 12 retained in the sleeve 16. In the closed position, an edge 42 of each of the flaps 40 a, 40 b, 40 c is configured to releasably engage a portion of the mouth 17 or the lid 19 to maintain an inwardly converging position of the flaps 40 a, 40 b, 40 c with respect to the sleeve 16. When the cover 20 is in the closed position, the flaps 40 a, 40 b, 40 c are disposed beneath the top wall 21 and substantially concealed by the top wall 21. In the embodiment shown, the sleeve 16 includes three flaps and the edges 42 of the flaps 40 a, 40 b, 40 c have an arcuate shape to correspond to a substantially circular shaped mouth 17. It is understood, the sleeve 16 can include any number of flaps 40 a, 40 b, 40 c such as one flap, two flaps, four flaps, five flaps, six flaps, eight flaps, etc.

As shown in FIG. 3, the shell 16 is formed from a one-piece blank 50 made from a corrugated material, flute styled corrugated fiberboard, or any other style corrugated fiberboard. However, similar paper-based materials, having similar performance characteristics, may be employed if desired as well as corrugated plastics or non-corrugated plastics, or other foldable material. The blank 50 includes a first panel 52, a second panel 54, a third panel 56, and a fourth panel 58 to form the respective sidewalls 26 a, 26 b, 26 c, 26 d. The panels 52, 54, 56, 58 are each hingedly coupled to at least one adjacent panel 52, 54, 56, 58 along fold lines 51. The fold lines 51 can be formed by perforations, scored marks, or any other means to hingedly couple the panels 52, 54. 56, 58 to each other. A securement tab 59 is hingedly coupled to the second panel 54 and configured to facilitate formation of the sidewalls 26 a, 26 b, 26 c, 26 d. The second pair of tabs 31 extend from the sides of the first panel 52.

The blank 50 further includes a first bottom flap 62 hingedly coupled to a first end of the first panel 52, a second bottom flap 64 hingedly coupled to a first end of the second panel 54, a third bottom flap 66 hingedly coupled to a first end of the third panel 56, and a fourth bottom flap 68 hingedly coupled to a first end of the fourth panel 58. The bottom flaps 62, 64, 66, 68 cooperate with each other to form the bottom 25 of the sleeve 16. The bottom flaps 62, 64, 66, 68 are each hingedly coupled to the respective panels 52, 54, 56, 58 along fold lines 61. The fold lines 61 can be formed by perforations, scored marks, or the like, for example. In certain embodiments, the second bottom flap 64 and the third bottom flap 66 can include securement tabs 69 hingedly coupled thereto to facilitate formation of the bottom 25 of the sleeve 16. Although, it is understand additional securement tabs 69 can be included on any of the bottom flaps, as desired.

The blank 50 further includes the flaps 40 a, 40 b, 40 c as described hereinabove. The first flap 40 a is hingedly coupled to a second end of the first panel 52, the second flap 40 b in hingedly coupled to a second end of the second panel 54, and the third flap 40 c is hingedly coupled to a second end of the third panel 56. The flaps 40 a, 40 b, 40 c are each hingedly coupled to the respective panels 52, 54, 56 along fold lines 41. The fold lines 41 can be formed by perforations, scored marks, or the like, for example.

A top panel 70 configured to form the cover 20 of the shell 16 is hingedly coupled to a second end of the fourth panel 58 along a fold line 71. The fold line 71 can be formed by perforations, scored marks, or the like, for example. The top panel 70 is divided into a first section 72, a second section 74, a third section 76, and a fourth section 78. The sections 72, 74, 76, 78 are hingedly coupled to each other along fold lines 81. The fold lines 81 can be formed by perforations, scored marks, or the like, for example.

The first section 72 is disposed adjacent the fold line 71 and forms the top wall 21 of the cover 20. The first section 72 includes the aperture 24 and the first pair of slits 34 for receiving the first pair of tabs 32 formed therein. In certain embodiments, the first section 72 additionally includes a knock-out portion 80 for forming the slot 22 of the cover 20 of the shell 16. The knock-out portion 80 is disposed adjacent the fold line 71 and is defined by a portion of the fold line 71 and a perforated line 82. However, it is understood, the knock-out portion 80 can be disposed at any portion of the top panel 70 as desired and can be configured to be completely removed or hingedly coupled to the first section 72.

The second section 74, the third section 76, and the fourth section 78 form the partitions 30 a, 30 b, 30 c, respectively. The third section 76 and the fourth section 78 each extend laterally from opposing sides of the first section 72 and each include one of the second pair of slits 33 formed therein. An engagement tab 90 is hingedly coupled to each of the third section 76 and the fourth section 78 along fold lines 91. The engagement tabs 90 are configured to facilitate formation of the cover 20. The second section 74 extends from the edge of the first section 72 opposing the fold line 71.

The second section 74 is divided into a first sub-section 84 adjacent the first section 72, a second sub-section 86, and a third sub-section 88. The sub-sections 84, 86, 88 are hingedly coupled to each other along perforated fold lines 92. The first sub-section 84 and the third sub-section 88 each have a width substantially equal to a width of the third section 76 and the fourth section 78. The second sub-section 86 is disposed intermediate the first subsection 84 and the third subsection 88 and has a width substantially equal to a thickness of the engagement tabs 90. The first pair of tabs 32 extend outwardly from the third sub-section 88. It is understood the top panel 70 can include other configurations as desired. For example, the top panel 70 can include any number of sections and subsections to form the cover 20.

To assemble the shell 16 from the blank 50, the sidewalls 26 a, 26 b, 26 c, 26 d are formed by folding the panels 52, 54, 56, 58 along the fold lines 51 and securing the securement tab 59 to the first panel 52. The bottom flaps 62, 64, 66, 68 are folded along the fold lines 61 and cooperate with each other to form the bottom 25 of the sleeve 16. The flaps 40 a, 40 b, 40 c are folded along the fold lines 41 to converge inwardly with respect to the shell 16. The top panel 70 is then manipulated to form the cover 20 of the shell 16.

To form the cover 20, the second section 74, the third section 76, and the fourth section 78 are folded along fold lines 81 towards the sidewalls 26 a, 26 b, 26 c, 26 d. The third section 76 and the fourth section 78 form the second partition 30 b and the third partition 30 c, respectively. The engagement tabs 90 are then folded along fold lines 91 towards each other to abut an inner surface of the second section 74 at the first sub-section 84 thereof. The second section 74 is folded upon itself along the fold lines 91 to envelope the engagement tabs 90 and form the first partition 30 a. The second section 74 envelopes the engagement tabs 90 so the first sub-section 84 is substantially parallel to the third sub-section 88 and the second sub-section 86 is substantially perpendicular to the first sub-section 84 and the third subsection 88. The first pair of tabs 32 cooperate with the first pair of slits 34 to maintain the second section 74 in a position enveloped about the engagement tabs 90 to form and reinforce the first partition 30 a.

Once formed, the cover 20 can then be folded about the fold line 71 to move from the open position to the closed position as desired. The second pair of tabs 31 cooperate with the second pair of slits 33 to maintain the cover 20 in the closed position. The knock-out portion 80 of the blank 50 can be separated along the perforated lines 82 and folded along the fold line 71 to form the slot 22 for receiving the utensil 15.

To assemble the container assembly 10, the receptacle 12 is positioned within the insulation layer 14 so that the insulation layer 14 either partially or entirely envelopes the receptacle 12. The sleeve 16 can be stored flat and easily opened by forming and securing the bottom 25. The receptacle 12 and insulation layer 14 are positioned within the sleeve 16 so the sleeve 16 covers a substantial portion of the receptacle 12 and insulation layer 14. The flaps 40 a, 40 b, 40 c are folded about the fold lines 41 and are urged to an inwardly converging position to engage with the mouth 17 of the receptacle 12 or the lid 19. The cover 20 is moved from the open position to the closed position so that the mouth 17 and the lid 19 are received through the aperture 24 formed therein. In certain embodiments, the substantially linear portion 23 b of the rim 23 engages with the mouth 17 and/or the lid 19 to maintain the cover 20 in the closed position.

Each of the ends of the handle 36 are inserted through a respective slot 38 formed in the second sidewall 26 b and the third sidewall 26 c so that the container assembly 10 can be easily and safely transported. The utensil 15 can be inserted through the slot 22.

In application, the receptacle 12 is filled with a food product such as hot soup. The mouth 17 of the receptacle 12 facilitates quick transfer of the food product to the receptacle 12. The lid 19 is coupled to the receptacle 12 to close the opening 18. Advantageously, the insulation layer 14 insulates the food product within the receptacle 12 thereby facilitating a minimal temperature drop over a period of time such as the time of travel from the food retailers to a designated delivery location. The sleeve 16 further facilitates insulation and provides a portable containing means for transporting food products. The configuration of the sleeve 16 is durable and easy to assemble.

In non-limiting examples, the container assembly 10 can militate against a temperature drop of more than 5-10 degrees Fahrenheit per hour. It is understood that the container assembly 10 can be assembled either prior to filling the receptacle 12 with the food product or after filling the receptacle 12 with the food product. In certain embodiments, the container assembly 10 can be pre-assembled and packaged and delivered in units of six or twelve, for example, to the food retailers, restaurants, caterers, etc. According to this embodiment, the retail food providers only are required to remove the lid 19, fill the receptacle 12 with the food product, replace the lid 19, and provide the take-out, delivery, or catered service.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. 

What is claimed is:
 1. A container assembly for use in containing a food product comprising: a receptacle having a mouth defining an opening; and a sleeve having a plurality of sidewalls forming a cavity and a cover engaging the sidewalls and covering the cavity, the cavity at least partially receiving the receptacle therein, the cover including an aperture for receiving the mouth of the receptacle therethrough.
 2. The container assembly of claim 1, further comprising an insulation layer at least partially enveloping the receptacle and retained by the sleeve.
 3. The container assembly of claim 1, wherein the sleeve is corrugated.
 4. The container assembly of claim 1, wherein the sleeve includes a flap hingedly coupled to the sleeve, the flap configured to converge towards and engage the mouth of the receptacle.
 5. The container assembly of claim 1, wherein a rim defines the aperture and the rim has a substantially linear portion engaging the receptacle to maintain the cover in a closed position.
 6. The container assembly of claim 1, wherein the cover includes a top wall and a plurality of partitions extending from the top wall, the plurality of partitions configured to partially overlap the sidewalls.
 7. The container assembly of claim 1, wherein the cover is hingedly coupled to one of the plurality of sidewalls.
 8. The container assembly of claim 1, wherein the cover includes a slot formed therein configured for receiving a utensil.
 9. The container assembly of claim 1, wherein the sleeve includes a handle coupled thereto.
 10. A container assembly for use in containing a food product comprising: a receptacle having a mouth defining an opening; an insulation layer at least partially enveloping the receptacle; and a sleeve having a plurality of sidewalls forming a cavity and a cover hingedly coupled with a first one of the sidewalls, the cavity at least partially receiving the receptacle and the insulation therein, the cover including an aperture for receiving the mouth of the receptacle therethrough.
 11. The container assembly of claim 10, wherein the sleeve is corrugated and the insulation layer is a preformed bubble foil wrap.
 12. The container assembly of claim 10, wherein the sleeve includes a flap hingedly coupled to a second one of the sidewalls
 13. The container assembly of claim 10, wherein the cover includes a slot formed therein configured for receiving a utensil and the sleeve includes a handle coupled thereto.
 14. The container assembly of claim 10, wherein a rim defines the aperture and the rim has a substantially linear portion engaging the receptacle and configured to maintain the cover in a closed position.
 15. The container assembly of claim 10, wherein the cover includes a top wall and a plurality of partitions extending from the top wall, the plurality of partitions configured to partially overlap the plurality of sidewalls.
 16. A method of assembling a container assembly comprising the steps of: providing a blank including a plurality of side panels, a plurality of bottom flaps each hingedly coupled to a first end of one of the plurality of side panels, and a top panel hingedly coupled to a second end of a first one of the side panels; arranging the side panels, the bottom flaps, and the top panel to form an outer shell having a plurality of sidewalls and a cover; providing a receptacle and an insulation layer, the receptacle having a mouth defining an opening configured for receiving a food product; enveloping the receptacle with the insulation layer; disposing the receptacle and the insulation layer in the outer shell; and positioning the top cover in a closed position.
 17. The method of claim 16, wherein the top panel includes a plurality of sections.
 18. The method of claim 17, further comprising the step of folding the plurality of sections to form a top wall of the cover and a plurality of partitions of the cover, the partitions extending from the top wall and configured to overlap a portion of the sidewalls.
 19. The method of claim 18, further comprising the step of folding at least one of the sections upon itself to envelope a portion of the cover.
 20. The method of claim 15, further comprising the step of filling the receptacle with a food product. 